Chamber systems for additive manufacturing

ABSTRACT

An apparatus and a method for powder bed fusion additive manufacturing involve a multiple-chamber design achieving a high efficiency and throughput. The multiple-chamber design features concurrent printing of one or more print jobs inside one or more build chambers, side removals of printed objects from build chambers allowing quick exchanges of powdered materials, and capabilities of elevated process temperature controls of build chambers and post processing heat treatments of printed objects. The multiple-chamber design also includes a height-adjustable optical assembly in combination with a fixed build platform method suitable for large and heavy printed objects.

CROSS-REFERENCE TO RELATED PATENT APPLICATION

The present disclosure is part of a non-provisional patent applicationclaiming the priority benefit of

U.S. Patent Application No. 62/248,758, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,765, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,770, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,776, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,783, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,791, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,799, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,966, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,968, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,969, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,980, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,989, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,780, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,787, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,795, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,821, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,829, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,833, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,835, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,839, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,841, filed on Oct. 30, 2015,

U.S. Patent Application No. 62/248,847, filed on Oct. 30, 2015, and

U.S. Patent Application No. 62/248,848, filed on Oct. 30, 2015, whichare incorporated by reference in its entirety.

TECHNICAL FIELD

The present disclosure generally relates to additive manufacturing and,more particularly, to powder bed fusion additive manufacturing chamberdesigns with high throughput capabilities.

BACKGROUND

Additive manufacturing, commonly known as 3D printing, are widely usedto lower cost and risk in manufacturing of prototypes. In particular,powder bed fusion additive manufacturing reduces the amount of rawmaterial used and places a lower burden on the resources and theenvironment. As more industrial sectors adopt additive manufacturing forproduct innovation or mass-production tools, limitations of efficiencyand throughput remain challenging to overcome. Contemporary powder bedfusion additive manufacturing systems may be operated in a batch-modestyle to print an object in a build chamber. Once a print job iscompleted, interruptions of operations are required for removing theprinted object and remaining powders in the build chamber, with apossibility of switching to a different powdered material. Moreover, theintensity of the light source and optical components may need to beadjusted, re-aligned, or re-configured for the new powdered material.This de-powering and activities of re-arrangements consumes a largefraction of overall machine available time, thereby adversely impactingutilization, efficiency, and ultimately the economics of additivemanufacturing.

BRIEF DESCRIPTION OF THE DRAWINGS

Non-limiting and non-exhaustive embodiments of the present disclosureare described with reference to the following figures, wherein likereference numerals refer to like parts throughout the various figuresunless otherwise specified.

FIG. 1A illustrates an additive manufacturing system;

FIG. 1B is a top view of a structure being formed on an additivemanufacturing system;

FIG. 2 illustrates an additive manufacturing method;

FIG. 3A is a cartoon illustrating an additive manufacturing systemincluding lasers;

FIG. 3B is a detailed description of the light patterning unit shown inFIG. 3A.;

FIG. 3C is one embodiment of an additive manufacturing system with a“switchyard” for directing and repatterning light using multiple imagerelays;

FIG. 3D illustrates a simple mirror image pixel remapping;

FIG. 3E illustrates a series of image transforming image relays forpixel remapping;

FIG. 3F illustrates an patternable electron energy beam additivemanufacturing system;

FIG. 3G illustrates a detailed description of the electron beampatterning unit shown in FIG. 3F;

FIG. 4 is an example scenario depicting a concurrent printing process inmultiple build chambers in accordance with an embodiment of the presentdisclosure;

FIG. 5 is an example scenario depicting a side removal of a powder bedupon completion of a print job in accordance with an embodiment of thepresent disclosure;

FIG. 6 is an example scenario depicting a control of depth of field byindexing the build platform downwards as layers of powders beingsuccessively dispensed in accordance with an embodiment of the presentdisclosure;

FIG. 7 is an example scenario depicting a control of depth of field bymoving the optical-mechanical assembly upwards as layers of powdersbeing successively dispensed in accordance with an embodiment of thepresent disclosure;

FIG. 8 is an example scenario illustrating upward movement of the gantrytable together with the powder dispensing unit relative to the fixedpowder bed during a build process;

FIG. 9 is an example scenario depicting a control of the temperature ofa powder bed inside a build chamber in accordance with an embodiment ofthe present disclosure;

FIG. 10 is block diagram depicting an example apparatus of a laser-basedpowder bed fusion additive manufacturing system in accordance with anembodiment of the present disclosure; and

FIG. 11 is a block diagram depicting a process flow of concurrentprinting in a powder bed fusion additive manufacturing system withmultiple build chambers in accordance with an embodiment of the presentdisclosure.

DETAILED DESCRIPTION

In the following description, reference is made to the accompanyingdrawings that form a part thereof, and in which is shown by way ofillustrating specific exemplary embodiments in which the disclosure maybe practiced. These embodiments are described in sufficient detail toenable those skilled in the art to practice the concepts disclosedherein, and it is to be understood that modifications to the variousdisclosed embodiments may be made, and other embodiments may beutilized, without departing from the scope of the present disclosure.The following detailed description is, therefore, not to be taken in alimiting sense.

The present disclosure describes a powder bed fusion additivemanufacturing system configured with multiple build chambers to enhanceefficiency and throughput rates. The build chambers also include a sideremoval mechanism for handling large and heavy printed objects.Moreover, elevated temperature controls and post processing heattreatments are feasible inside the build chambers.

In various embodiments in accordance with the present disclosure, apowder bed fusion additive manufacturing system configured with multiplebuild chambers may allow concurrent printing of one or more objectsinside different build chambers. The multiple-chamber approach mayreduce overhead associated with switching powdered materials inside abuild chamber for printing different objects. The build chambers may beequipped with a side removal mechanism that improves handling andefficiency for printing large and heavy objects. Heating/coolingelements and temperature sensors may be embedded inside the buildchamber to control process temperatures during concurrent printing orpost processing heat treatments.

An additive manufacturing system is disclosed which has one or moreenergy sources, including in one embodiment, one or more laser orelectron beams, positioned to emit one or more energy beams. Beamshaping optics may receive the one or more energy beams from the energysource and form a single beam. An energy patterning unit receives orgenerates the single beam and transfers a two-dimensional pattern to thebeam, and may reject the unused energy not in the pattern. An imagerelay receives the two-dimensional patterned beam and focuses it as atwo-dimensional image to a desired location on a height fixed or movablebuild platform (e.g. a powder bed). In certain embodiments, some or allof any rejected energy from the energy patterning unit is reused.

In some embodiments, multiple beams from the laser array(s) are combinedusing a beam homogenizer. This combined beam can be directed at anenergy patterning unit that includes either a transmissive or reflectivepixel addressable light valve. In one embodiment, the pixel addressablelight valve includes both a liquid crystal module having a polarizingelement and a light projection unit providing a two-dimensional inputpattern. The two-dimensional image focused by the image relay can besequentially directed toward multiple locations on a powder bed to builda 3D structure.

As seen in FIG. 1, an additive manufacturing system 100 has an energypatterning system 110 with an energy source 112 that can direct one ormore continuous or intermittent energy beam(s) toward beam shapingoptics 114. After shaping, if necessary, the beam is patterned by anenergy patterning unit 116, with generally some energy being directed toa rejected energy handling unit 118. Patterned energy is relayed byimage relay 120 toward an article processing unit 140, typically as atwo-dimensional image 122 focused near a bed 146. The bed 146 (withoptional walls 148) can form a chamber containing material 144 dispensedby material dispenser 142. Patterned energy, directed by the image relay120, can melt, fuse, sinter, amalgamate, change crystal structure,influence stress patterns, or otherwise chemically or physically modifythe dispensed material 144 to form structures with desired properties.

Energy source 112 generates photon (light), electron, ion, or othersuitable energy beams or fluxes capable of being directed, shaped, andpatterned. Multiple energy sources can be used in combination. Theenergy source 112 can include lasers, incandescent light, concentratedsolar, other light sources, electron beams, or ion beams. Possible lasertypes include, but are not limited to: Gas Lasers, Chemical Lasers, DyeLasers, Metal Vapor Lasers, Solid State Lasers (e.g. fiber),Semiconductor (e.g. diode) Lasers, Free electron laser, Gas dynamiclaser, “Nickel-like” Samarium laser, Raman laser, or Nuclear pumpedlaser.

A Gas Laser can include lasers such as a Helium—neon laser, Argon laser,Krypton laser, Xenon ion laser, Nitrogen laser, Carbon dioxide laser,Carbon monoxide laser or Excimer laser.

A Chemical laser can include lasers such as a Hydrogen fluoride laser,Deuterium fluoride laser, COIL (Chemical oxygen—iodine laser), or Agil(All gas-phase iodine laser).

A Metal Vapor Laser can include lasers such as a Helium-cadmium (HeCd)metal-vapor laser, Helium-mercury (HeHg) metal-vapor laser,Helium-selenium (HeSe) metal-vapor laser, Helium-silver (HeAg)metal-vapor laser, Strontium Vapor Laser, Neon-copper (NeCu) metal-vaporlaser, Copper vapor laser, Gold vapor laser, or Manganese (Mn/MnCl₂)vapor laser.

A Solid State Laser can include lasers such as a Ruby laser, Nd:YAGlaser, NdCrYAG laser, Er:YAG laser, Neodymium YLF (Nd:YLF) solid-statelaser, Neodymium doped Yttrium orthovanadate(Nd:YVO₄) laser, Neodymiumdoped yttrium calcium oxoborateNd:YCa₄O(BO₃)³ or simply Nd:YCOB,Neodymium glass(Nd:Glass) laser, Titanium sapphire(Ti:sapphire) laser,Thulium YAG (Tm:YAG) laser, Ytterbium YAG (Yb:YAG) laser, Ytterbium:2O₃(glass or ceramics) laser, Ytterbium doped glass laser (rod, plate/chip,and fiber), Holmium YAG (Ho:YAG) laser, Chromium ZnSe (Cr:ZnSe) laser,Cerium doped lithium strontium (or calcium)aluminum fluoride(Ce:LiSAF,Ce:LiCAF), Promethium 147 doped phosphate glass(147 Pm⁺³:Glass)solid-state laser, Chromium doped chrysoberyl (alexandrite) laser,Erbium doped anderbium-ytterbium co-doped glass lasers, Trivalenturanium doped calcium fluoride (U:CaF₂) solid-state laser, Divalentsamarium doped calcium fluoride(Sm:CaF₂) laser, or F-Center laser.

A Semiconductor Laser can include laser medium types such as GaN, InGaN,AlGaInP, AlGaAs, InGaAsP, GaInP, InGaAs, InGaAsO, GaInAsSb, lead salt,Vertical cavity surface emitting laser (VCSEL), Quantum cascade laser,Hybrid silicon laser, or combinations thereof.

For example, in one embodiment a single Nd:YAG q-switched laser can beused in conjunction with multiple semiconductor lasers. In anotherembodiment, an electron beam can be used in conjunction with anultraviolet semiconductor laser array. In still other embodiments, atwo-dimensional array of lasers can be used. In some embodiments withmultiple energy sources, pre-patterning of an energy beam can be done byselectively activating and deactivating energy sources.

Beam shaping unit 114 can include a great variety of imaging optics tocombine, focus, diverge, reflect, refract, homogenize, adjust intensity,adjust frequency, or otherwise shape and direct one or more energy beamsreceived from the energy source 112 toward the energy patterning unit116. In one embodiment, multiple light beams, each having a distinctlight wavelength, can be combined using wavelength selective mirrors(e.g. dichroics) or diffractive elements. In other embodiments, multiplebeams can be homogenized or combined using multifaceted mirrors,microlenses, and refractive or diffractive optical elements.

Energy patterning unit 116 can include static or dynamic energypatterning elements. For example, photon, electron, or ion beams can beblocked by masks with fixed or movable elements. To increase flexibilityand ease of image patterning, pixel addressable masking, imagegeneration, or transmission can be used. In some embodiments, the energypatterning unit includes addressable light valves, alone or inconjunction with other patterning mechanisms to provide patterning. Thelight valves can be transmissive, reflective, or use a combination oftransmissive and reflective elements. Patterns can be dynamicallymodified using electrical or optical addressing. In one embodiment, atransmissive optically addressed light valve acts to rotate polarizationof light passing through the valve, with optically addressed pixelsforming patterns defined by a light projection source. In anotherembodiment, a reflective optically addressed light valve includes awrite beam for modifying polarization of a read beam. In yet anotherembodiment, an electron patterning device receives an address patternfrom an electrical or photon stimulation source and generates apatterned emission of electrons.

Rejected energy handling unit 118 is used to disperse, redirect, orutilize energy not patterned and passed through the energy pattern imagerelay 120. In one embodiment, the rejected energy handling unit 118 caninclude passive or active cooling elements that remove heat from theenergy patterning unit 116. In other embodiments, the rejected energyhandling unit can include a “beam dump” to absorb and convert to heatany beam energy not used in defining the energy pattern. In still otherembodiments, rejected beam energy can be recycled using beam shapingoptics 114. Alternatively, or in addition, rejected beam energy can bedirected to the article processing unit 140 for heating or furtherpatterning. In certain embodiments, rejected beam energy can be directedto additional energy patterning systems or article processing units.

Image relay 120 receives a patterned image (typically two-dimensional)from the energy patterning unit 116 and guides it toward the articleprocessing unit 140. In a manner similar to beam shaping optics 114, theimage relay 120 can include optics to combine, focus, diverge, reflect,refract, adjust intensity, adjust frequency, or otherwise shape anddirect the patterned image.

Article processing unit 140 can include a walled chamber 148 and bed144, and a material dispenser 142 for distributing material. Thematerial dispenser 142 can distribute, remove, mix, provide gradationsor changes in material type or particle size, or adjust layer thicknessof material. The material can include metal, ceramic, glass, polymericpowders, other melt-able material capable of undergoing a thermallyinduced phase change from solid to liquid and back again, orcombinations thereof. The material can further include composites ofmelt-able material and non-melt-able material where either or bothcomponents can be selectively targeted by the imaging relay system tomelt the component that is melt-able, while either leaving along thenon-melt-able material or causing it to undergo avaporizing/destroying/combusting or otherwise destructive process. Incertain embodiments, slurries, sprays, coatings, wires, strips, orsheets of materials can be used. Unwanted material can be removed fordisposable or recycling by use of blowers, vacuum systems, sweeping,vibrating, shaking, tipping, or inversion of the bed 146.

In addition to material handling components, the article processing unit140 can include components for holding and supporting 3D structures,mechanisms for heating or cooling the chamber, auxiliary or supportingoptics, and sensors and control mechanisms for monitoring or adjustingmaterial or environmental conditions. The article processing unit can,in whole or in part, support a vacuum or inert gas atmosphere to reduceunwanted chemical interactions as well as to mitigate the risks of fireor explosion (especially with reactive metals).

Control processor 150 can be connected to control any components ofadditive manufacturing system 100. The control processor 150 can beconnected to variety of sensors, actuators, heating or cooling systems,monitors, and controllers to coordinate operation. A wide range ofsensors, including imagers, light intensity monitors, thermal, pressure,or gas sensors can be used to provide information used in control ormonitoring. The control processor can be a single central controller, oralternatively, can include one or more independent control systems. Thecontroller processor 150 is provided with an interface to allow input ofmanufacturing instructions. Use of a wide range of sensors allowsvarious feedback control mechanisms that improve quality, manufacturingthroughput, and energy efficiency.

FIG. 1B is a cartoon illustrating a bed 146 that supports material 144.Using a series of sequentially applied, two-dimensional patterned energybeam images (squares in dotted outline 124), a structure 149 isadditively manufactured. As will be understood, image patterns havingnon-square boundaries can be used, overlapping or interpenetratingimages can be used, and images can be provided by two or more energypatterning systems. In other embodiments, images can be formed inconjunction with directed electron or ion beams, or with printed orselective spray systems.

FIG. 2 is a flow chart illustrating one embodiment of an additivemanufacturing process supported by the described optical and mechanicalcomponents. In step 202, material is positioned in a bed, chamber, orother suitable support. The material can be a powder capable of beingmelted, fused, sintered, induced to change crystal structure, havestress patterns influenced, or otherwise chemically or physicallymodified to form structures with desired properties.

In step 204, unpatterned energy is emitted by one or more energyemitters, including but not limited to solid state or semiconductorlasers, or electrical power supply flowing electrons down a wire. Instep 206, the unpatterned energy is shaped and modified (e.g. intensitymodulated or focused). In step 208, this unpatterned energy ispatterned, with energy not forming a part of the pattern being handledin step 210 (this can include conversion to waste heat, or recycling aspatterned or unpatterned energy). In step 212, the patterned energy, nowforming a two-dimensional image is relayed toward the material. In step214, the image is applied to the material, building a portion of a 3Dstructure. These steps can be repeated (loop 218) until the image (ordifferent and subsequent image) has been applied to all necessaryregions of a top layer of the material. When application of energy tothe top layer of the material is finished, a new layer can be applied(loop 216) to continue building the 3D structure. These process loopsare continued until the 3D structure is complete, when remaining excessmaterial can be removed or recycled.

FIG. 3A is one embodiment of an additive manufacturing system 300 thatuses multiple semiconductor lasers as part of an energy patterningsystem 310. A control processor 350 can be connected to variety ofsensors, actuators, heating or cooling systems, monitors, andcontrollers to coordinate operation of multiple lasers 312, lightpatterning unit 316, and image relay 320, as well as any other componentof system 300. These connections are generally indicated by a dottedoutline 351 surrounding components of system 300. As will beappreciated, connections can be wired or wireless, continuous orintermittent, and include capability for feedback (for example, thermalheating can be adjusted in response to sensed temperature). The multiplelasers 312 can emit a beam 301 of light at a 1000 nm wavelength that,for example, is 90 mm wide by 20 mm tall. The beam 301 is resized byimaging optics 370 to create beam 303. Beam 303 is 6 mm wide by 6 mmtall, and is incident on light homogenization device 372 which blendslight together to create blended beam 305. Beam 305 is then incident onimaging assembly 374 which reshapes the light into beam 307 and is thenincident on hot cold mirror 376. The mirror 376 allows 1000 nm light topass, but reflects 450 nm light. A light projector 378 capable ofprojecting low power light at 1080 p pixel resolution and 450 nm emitsbeam 309, which is then incident on hot cold mirror 376. Beams 307 and309 overlay in beam 311, and both are imaged onto optically addressedlight valve 380 in a 20 mm wide, 20 mm tall image. Images formed fromthe homogenizer 372 and the projector 378 are recreated and overlaid onlight valve 380.

The optically addressed light valve 380 is stimulated by the light(typically ranging from 400-500 nm) and imprints a polarization rotationpattern in transmitted beam 313 which is incident upon polarizer 382.The polarizer 382 splits the two polarization states, transmittingp-polarization into beam 317 and reflecting s-polarization into beam 315which is then sent to a beam dump 318 that handles the rejected energy.As will be understood, in other embodiments the polarization could bereversed, with s-polarization formed into beam 317 and reflectingp-polarization into beam 315. Beam 317 enters the final imaging assembly320 which includes optics 384 that resize the patterned light. This beamreflects off of a movable mirror 386 to beam 319, which terminates in afocused image applied to material bed 344 in an article processing unit340. The depth of field in the image selected to span multiple layers,providing optimum focus in the range of a few layers of error or offset.

The bed 390 can be raised or lowered (vertically indexed) within chamberwalls 388 that contain material 344 dispensed by material dispenser 342.In certain embodiments, the bed 390 can remain fixed, and optics of thefinal imaging assembly 320 can be vertically raised or lowered. Materialdistribution is provided by a sweeper mechanism 392 that can evenlyspread powder held in hopper 394, being able to provide new layers ofmaterial as needed. An image 6 mm wide by 6 mm tall can be sequentiallydirected by the movable mirror 386 at different positions of the bed.

When using a powdered ceramic or metal material in this additivemanufacturing system 300, the powder can be spread in a thin layer,approximately 1-3 particles thick, on top of a base substrate (andsubsequent layers) as the part is built. When the powder is melted,sintered, or fused by a patterned beam 319, it bonds to the underlyinglayer, creating a solid structure. The patterned beam 319 can beoperated in a pulsed fashion at 40 Hz, moving to the subsequent 6 mm×6mm image locations at intervals of 10 ms to 0.5 ms (with 3 to 0.1 msbeing desirable) until the selected patterned areas of powder have beenmelted. The bed 390 then lowers itself by a thickness corresponding toone layer, and the sweeper mechanism 392 spreads a new layer of powderedmaterial. This process is repeated until the 2D layers have built up thedesired 3D structure. In certain embodiments, the article processingunit 340 can have a controlled atmosphere. This allows reactivematerials to be manufactured in an inert gas, or vacuum environmentwithout the risk of oxidation or chemical reaction, or fire or explosion(if reactive metals are used).

FIG. 3B illustrates in more detail operation of the light patterningunit 316 of FIG. 3A. As seen in FIG. 3B, a representative input pattern333 (here seen as the numeral “9”) is defined in an 8×12 pixel array oflight projected as beam 309 toward mirror 376. Each grey pixelrepresents a light filled pixel, while white pixels are unlit. Inpractice, each pixel can have varying levels of light, includinglight-free, partial light intensity, or maximal light intensity.Unpatterned light 331 that forms beam 307 is directed and passes througha hot/cold mirror 376, where it combines with patterned beam 309. Afterreflection by the hot/cold mirror 376, the patterned light beam 311formed from overlay of beams 307 and 309 in beam 311, and both areimaged onto optically addressed light valve 380. The optically addressedlight valve 380, which would rotate the polarization state ofunpatterned light 331, is stimulated by the patterned light beam 309,311 to selectively not rotate the polarization state of polarized light307, 311 in the pattern of the numeral “9” into beam 313. The unrotatedlight representative of pattern 333 in beam 313 is then allowed to passthrough polarizer mirror 382 resulting in beam 317 and pattern 335.Polarized light in a second rotated state is rejected by polarizermirror 382, into beam 315 carrying the negative pixel pattern 337consisting of a light-free numeral “9”.

Other types of light valves can be substituted or used in combinationwith the described light valve. Reflective light valves, or light valvesbase on selective diffraction or refraction can also be used. In certainembodiments, non-optically addressed light valves can be used. These caninclude but are not limited to electrically addressable pixel elements,movable mirror or micro-mirror systems, piezo or micro-actuated opticalsystems, fixed or movable masks, or shields, or any other conventionalsystem able to provide high intensity light patterning. For electronbeam patterning, these valves may selectively emit electrons based on anaddress location, thus imbuing a pattern on the beam of electronsleaving the valve.

FIG. 3C is one embodiment of an additive manufacturing system thatincludes a switchyard system enabling reuse of patterned two-dimensionalenergy. Similar to the embodiment discussed with respect to FIG. 1A, anadditive manufacturing system 220 has an energy patterning system withan energy source 112 that directs one or more continuous or intermittentenergy beam(s) toward beam shaping optics 114. After shaping, the beamis two-dimensionally patterned by an energy patterning unit 230, withgenerally some energy being directed to a rejected energy handling unit222. Patterned energy is relayed by one of multiple image relays 232toward one or more article processing units 234A, 234B, 234C, or 234D,typically as a two-dimensional image focused near a movable or fixedheight bed. The bed (with optional walls) can form a chamber containingmaterial dispensed by material dispenser. Patterned energy, directed bythe image relays 232, can melt, fuse, sinter, amalgamate, change crystalstructure, influence stress patterns, or otherwise chemically orphysically modify the dispensed material to form structures with desiredproperties.

In this embodiment, the rejected energy handling unit has multiplecomponents to permit reuse of rejected patterned energy. Relays 228A,228B, and 22C can respectively transfer energy to an electricitygenerator 224, a heat/cool thermal management system 225, or an energydump 226. Optionally, relay 228C can direct patterned energy into theimage relay 232 for further processing. In other embodiments, patternedenergy can be directed by relay 228C, to relay 228B and 228A forinsertion into the energy beam(s) provided by energy source 112. Reuseof patterned images is also possible using image relay 232. Images canbe redirected, inverted, mirrored, sub-patterned, or otherwisetransformed for distribution to one or more article processing units.234A-D. Advantageously, reuse of the patterned light can improve energyefficiency of the additive manufacturing process, and in some casesimprove energy intensity directed at a bed, or reduce manufacture time.

FIG. 3D is a cartoon 235 illustrating a simple geometricaltransformation of a rejected energy beam for reuse. An input pattern 236is directed into an image relay 237 capable of providing a mirror imagepixel pattern 238. As will be appreciated, more complex pixeltransformations are possible, including geometrical transformations, orpattern remapping of individual pixels and groups of pixels. Instead ofbeing wasted in a beam dump, this remapped pattern can be directed to anarticle processing unit to improve manufacturing throughput or beamintensity.

FIG. 3E is a cartoon 235 illustrating multiple transformations of arejected energy beam for reuse. An input pattern 236 is directed into aseries of image relays 237B-E capable of providing a pixel pattern 238.

FIG. 3F and 3G illustrates a non-light based energy beam system 240 thatincludes a patterned electron beam 241 capable of producing, forexample, a “P” shaped pixel image. A high voltage electricity powersystem 243 is connected to an optically addressable patterned cathodeunit 245. In response to application of a two-dimensional patternedimage by projector 244, the cathode unit 245 is stimulated to emitelectrons wherever the patterned image is optically addressed. Focusingof the electron beam pattern is provided by an image relay system 247that includes imaging coils 246A and 246B. Final positioning of thepatterned image is provided by a deflection coil 248 that is able tomove the patterned image to a desired position on a bed of additivemanufacturing component 249.

In another embodiment supporting light recycling and reuse, multiplexmultiple beams of light from one or more light sources are provided. Themultiple beams of light may be reshaped and blended to provide a firstbeam of light. A spatial polarization pattern may be applied on thefirst beam of light to provide a second beam of light. Polarizationstates of the second beam of light may be split to reflect a third beamof light, which may be reshaped into a fourth beam of light. The fourthbeam of light may be introduced as one of the multiple beams of light toresult in a fifth beam of light. In effect, this or similar systems canreduce energy costs associated with an additive manufacturing system. Bycollecting, beam combining, homogenizing and re-introducing unwantedlight rejected by a spatial polarization valve or light valve operatingin polarization modification mode, overall transmitted light power canpotentially be unaffected by the pattern applied by a light valve. Thisadvantageously results in an effective re-distribution of the lightpassing through the light valve into the desired pattern, increasing thelight intensity proportional to the amount of area patterned.

Combining beams from multiple lasers into a single beam is one way toincreasing beam intensity. In one embodiment, multiple light beams, eachhaving a distinct light wavelength, can be combined using eitherwavelength selective mirrors or diffractive elements. In certainembodiments, reflective optical elements that are not sensitive towavelength dependent refractive effects can be used to guide amultiwavelength beam.

Patterned light can be directed using movable mirrors, prisms,diffractive optical elements, or solid state optical systems that do notrequire substantial physical movement. In one embodiment, amagnification ratio and an image distance associated with an intensityand a pixel size of an incident light on a location of a top surface ofa powder bed can be determined for an additively manufactured,three-dimensional (3D) print job. One of a plurality of lens assembliescan be configured to provide the incident light having the magnificationratio, with the lens assemblies both a first set of optical lenses and asecond sets of optical lenses, and with the second sets of opticallenses being swappable from the lens assemblies. Rotations of one ormore sets of mirrors mounted on compensating gantries and a final mirrormounted on a build platform gantry can be used to direct the incidentlight from a precursor mirror onto the location of the top surface ofthe powder bed. Translational movements of compensating gantries and thebuild platform gantry are also able to ensure that distance of theincident light from the precursor mirror to the location of the topsurface of the powder bed is substantially equivalent to the imagedistance. In effect, this enables a quick change in the optical beamdelivery size and intensity across locations of a build area fordifferent powdered materials while ensuring high availability of thesystem.

In certain embodiments, a plurality of build chambers, each having abuild platform to hold a powder bed, can be used in conjunction withmultiple optical-mechanical assemblies arranged to receive and directthe one or more incident energy beams into the build chambers. Multiplechambers allow for concurrent printing of one or more print jobs insideone or more build chambers. In other embodiments, a removable chambersidewall can simplify removal of printed objects from build chambers,allowing quick exchanges of powdered materials. The chamber can also beequipped with an adjustable process temperature controls.

In another embodiment, one or more build chambers can have a buildchamber that is maintained at a fixed height, while optics arevertically movable. A distance between final optics of a lens assemblyand a top surface of powder bed a may be managed to be essentiallyconstant by indexing final optics upwards, by a distance equivalent to athickness of a powder layer, while keeping the build platform at a fixedheight. Advantageously, as compared to a vertically moving the buildplatform, large and heavy objects can be more easily manufactured, sinceprecise micron scale movements of the build platform are not needed.Typically, build chambers intended for metal powders with a volume morethan˜0.1-0.2 cubic meters (i.e., greater than 100-200 liters or heavierthan 500-1,000 kg) will most benefit from keeping the build platform ata fixed height.

In one embodiment, a portion of the layer of the powder bed may beselectively melted or fused to form one or more temporary walls out ofthe fused portion of the layer of the powder bed to contain anotherportion of the layer of the powder bed on the build platform. Inselected embodiments, a fluid passageway can be formed in the one ormore first walls to enable improved thermal management.

Improved powder handling can be another aspect of an improved additivemanufacturing system. A build platform supporting a powder bed can becapable of tilting, inverting, and shaking to separate the powder bedsubstantially from the build platform in a hopper. The powdered materialforming the powder bed may be collected in a hopper for reuse in laterprint jobs. The powder collecting process may be automated, andvacuuming or gas jet systems also used to aid powder dislodgement andremoval

Some embodiments of the disclosed additive manufacturing system can beconfigured to easily handle parts longer than an available chamber. Acontinuous (long) part can be sequentially advanced in a longitudinaldirection from a first zone to a second zone. In the first zone,selected granules of a granular material can be amalgamated. In thesecond zone, unamalgamated granules of the granular material can beremoved. The first portion of the continuous part can be advanced fromthe second zone to a third zone, while a last portion of the continuouspart is formed within the first zone and the first portion is maintainedin the same position in the lateral and transverse directions that thefirst portion occupied within the first zone and the second zone. Ineffect, additive manufacture and clean-up (e.g., separation and/orreclamation of unused or unamalgamated granular material) may beperformed in parallel (i.e., at the same time) at different locations orzones on a part conveyor, with no need to stop for removal of granularmaterial and/or parts.

In another embodiment, additive manufacturing capability can be improvedby use of an enclosure restricting an exchange of gaseous matter betweenan interior of the enclosure and an exterior of the enclosure. Anairlock provides an interface between the interior and the exterior;with the interior having multiple additive manufacturing chambers,including those supporting power bed fusion. A gas management systemmaintains gaseous oxygen within the interior at or below a limitingoxygen concentration, increasing flexibility in types of powder andprocessing that can be used in the system.

In another manufacturing embodiment, capability can be improved byhaving a 3D printer contained within an enclosure, the printer able tocreate a part having a weight greater than or equal to 2,000 kilograms.A gas management system may maintain gaseous oxygen within the enclosureat concentrations below the atmospheric level. In some embodiments, awheeled vehicle may transport the part from inside the enclosure,through an airlock, since the airlock operates to buffer between agaseous environment within the enclosure and a gaseous environmentoutside the enclosure, and to a location exterior to both the enclosureand the airlock.

Other manufacturing embodiments involve collecting powder samples inreal-time in a powder bed fusion additive manufacturing system. Aningester system is used for in-process collection and characterizationsof powder samples. The collection may be performed periodically and theresults of characterizations result in adjustments to the powder bedfusion process. The ingester system can optionally be used for one ormore of audit, process adjustments or actions such as modifying printerparameters or verifying proper use of licensed powder materials.

Yet another improvement to an additive manufacturing process can beprovided by use of a manipulator device such as a crane, lifting gantry,robot arm, or similar that allows for the manipulation of parts thatwould be difficult or impossible for a human to move is described. Themanipulator device can grasp various permanent or temporary additivelymanufactured manipulation points on a part to enable repositioning ormaneuvering of the part.

FIG. 4 illustrates an example scenario 400 in which a multiple-chamberapproach of powder bed fusion additive manufacturing in accordance withthe present disclosure may be utilized. Scenario 400 is an illustrativeexample of concurrent printing of one or more objects inside one or morerespective build chambers 420-426. Each of the build chambers 420-426may use one or more different powdered materials for a print job eachtime or may be dedicated to one powdered material to reduce overheadassociated with switching powdered materials (such as cleaning to avoidreactions and cross-contaminations between powdered materials). Thebuild chambers 420-426 may have different sizes to best utilize spacesinside the build chambers 420-426 by allocating print jobs according tothe sizes of objects to be printed. Scenario 400 may be operated withoutde-powering of major components such as print head 410. Print head 410may contain an energy source, energy patterning system, and image relaysuch as discussed with respect to FIG. 1 of the disclosure. Configuredwith multiple build chambers, in scenario 400 there is an option toswitch print head 410 to other build chambers for a next print job inqueue once a current print job is finished, thus eliminating down timecaused by the need of removing the printed object and powders in asingle-chamber configuration.

A novel approach of modular multiple-chamber printing is alsoillustrated in scenario 400. The energy source inside print head 410 maybe split into multiple incident beams. Print head 410 may contain one ormore beam steering drivers capable of directing multiple incident beamsto address one or more of the surrounding build chambers 420-426. InFIG. 4, beam 450 and beam 452 are directed by beam steering driversinside print head 410 towards build chamber 420 and build chamber 424.Build chambers 420-426 may contain powdered materials. Build chambers420-426 may have different sizes. For example, build chambers 420 and424 may be 1 meter on each side for a total print area of 1 squaremeter, and build chambers 422 and 426 may be 80 cm by 140 cm for a totalprint area of 1.12 square meter. Each of build chambers 420-426 may beequipped with a respective one of optical-mechanical assemblies 430-436to receive and further direct the incident beams onto the respectivebuild area. In of the example shown in scenario 400, optical assembly430 receives beam 450 from print head 410 and optical assembly 434receives beam 452 from print head 410, respectively. Optical assembly430 and optical assembly 434 may further direct and focus beam 450 andbeam 452 onto respective print surfaces inside build chamber 420 andbuild chamber 424, respectively, to carry out melting processes. In ofthe example shown in scenario 400, the print head 410 may be designed toprint tungsten in build chamber 420 and titanium in build chamber 424,with less energy required in printing titanium. An incident beam emittedby the energy source in print head 410 is split to form beam 450 towardbuild chamber 420 and beam 452 towards build chamber 424. Energy of beam452 may have less intensity than energy of beam 450 since titanium has alower melting point than tungsten. The total intensity of beam 450 andbeam 452 may not exceed the maximum output of the energy source insideprint head 410.

Powder bed fusion additive manufacturing systems build up objects byspreading a thin layer of a powdered material across a build platformand using an energy source to melt or sinter the powder where desired tocreate a two-dimensional slice of the object. Lasers may be operatedwith an optical assembly having a large focal length (depth of field),and as such the optical assembly are typically spaced far from the focalpoint of the build platform in powder bed fusion additive manufacturingsystems equipped with fiber lasers. Laser powder bed fusionmanufacturing systems also make top or bottom loading of the powder bedpossible within a sealed rectangular or circular walled chamber due tothe large focal length.

Semiconductor or diode lasers have a much higher divergence than typicallasers and such, require an optical assembly near the powder bed workingin small focal length between the final optic and the print surface.Semiconductor lasers may have other advantages over solid state (e.g.fiber) lasers such as higher efficiency and lower cost per watt, but thesmall focal length makes traditional top removal of objects larger thanthe focal length of the semiconductor lasers difficult. It is thereforedesirable to use a side access or an access from below for the removalof the powder bed and any printed objects from the build chamber.

FIG. 5 illustrates an example scenario 500 depicting a side removal of apowder bed upon completion of a print job in accordance with anembodiment of the present disclosure. In FIG. 5, a build chamber inaccordance with the present disclosure is capable of side removal ofpowder bed 522 supported by a build platform 530, as shown in part (B)of FIG. 5. The build chamber may include fixed wall 510, wall 512, wall514 and a removable door 516. Part (A) of FIG. 5 depicts build platform530 holding powder bed 520 at a starting position before a build processbegins. As shown in part (B) of FIG. 5, side removal of build platform530 holding powder bed 522 after the build process is feasible. Buildplatform 530 may have an area of 1 meter by 1 meter. Powder bed 522 isthicker than powder bed 520 due to successive depositions of powderlayers during the build process. Build platform 530 may be capable of upand down movements in the vertical direction during the build processsuch that the build chamber may be used in either configuration, whetherequipped with semiconductor or solid state lasers, electron beams, oranother suitable energy source. Door 516 may be closed to seal the buildchamber in a controlled atmosphere during the build process.

Furthermore, the build chamber in accordance with the present disclosuredescribed herein may be configured for quick exchanges of buildplatforms so that a build platform with a fully built powder bed may beemptied and reset in a separate offline process, while a new and emptybuild platform may be reloaded quickly to begin a new print cycle. Buildplatform 530 and door 516 may be removed or reloaded on rails, wheels,or manually. This improves utilization of relatively expensive lasersand build chambers, thereby achieving higher efficiency, throughput, andeconomic benefits.

The powder bed fusion technique employed for additive manufacturing usespowders that are selectively melted on each layer prior to a new powderlayer being added. High resolution printing may require that thedistance between the final optics of the laser and the print surface(i.e., the final throw) be managed within a very tight tolerance (thedepth of field). As each new powder layer is dispensed, an averagerelative motion equal to the thickness of each new layer may be requiredbetween the top surface (print surface) of the powder bed and the finaloptics of the laser.

FIG. 6 illustrates an example scenario 600 of controlling a final throw(depth of field) by indexing build platform 630 downwards. Part (A) ofFIG. 6 depicts a build platform 630 at a beginning or early-cycleposition holding powder bed 620, which is relatively thin. Wall 610 andwall 612 are two sidewalls of the build chamber where build platform 630is seated. Final optics 640 may receive and focus incident beam 650 ontoa top surface (print surface) of powder bed 620. Final optics 640 may bepart of optical-mechanical assembly 430, 432, 434 and/or 436 in examplescenario 400. Distance 660 between final optics 640 and the top surfaceof powder bed 620 may be managed to be essentially constant by indexingbuild platform 630 downwards, by a distance equivalent to a thickness ofa powder layer, as shown by arrow 670. Part (B) of FIG. 6 depicts buildplatform 630 at a final or late-cycle position holding powder bed 622which is relatively thicker than powder bed 620. Build platform 630 inpart (B) of FIG. 6 indexes downwards as each successive powder layer isdispensed over powder bed 622 to keep distance 662 relatively unchangedfrom distance 660 shown in part (A) of FIG. 6.

FIG. 7 illustrate another example scenario 700, in accordance with thepresent disclosure, of controlling a final throw (depth of field) bykeeping a build platform 730 at a fixed height and indexing othernecessary components upwards. Part (A) of FIG. 7 depicts build platform730 at a beginning or early-cycle position holding powder bed 720, whichis relatively thin. Wall 710 and wall 712 are two sidewalls of the buildchamber where build platform 730 is seated. Final optics 740 may receiveand focus incident beam 750 onto a top surface (print surface) of powderbed 720. Final optics 740 may be part of optical-mechanical assembly430, 432, 434 and/or 436 in example scenario 400. Distance 760 betweenfinal optics 740 and the top surface of powder bed 720 may be managed tobe essentially constant by indexing final optics 740 upwards, by adistance equivalent to a thickness of a powder layer, as shown by arrow770, while keeping build platform 730 at a fixed height. Part (B) ofFIG. 7 depicts build platform 730 at a final or late-cycle positionholding powder bed 722, which is relatively thicker than powder bed 720.Final optics 740 in part (B) of FIG. 7 indexes upwards as eachsuccessive powder layer is dispensed over powder bed 722 to keepdistance 762 relatively unchanged from distance 760 shown in part (A) ofFIG. 7.

Example scenario 700 carries advantages over example scenario 600 inbuilding large and heavy objects as it may be quicker and more costeffective to move lighter components in a powder bed fusion additivemanufacturing system. As an example, consider that the density of steelis approximately 7,850 kg/m³, and steel powder is typically ˜60% of fulldensity. The weight of the print head, powder dispensing unit, andportion of their supporting structure including the optical assemblygenerally may weigh considerably less than 500-1,000 kg. Consequently,build chambers intended for steel with a volume more than˜0.1-0.2 cubicmeters (i.e., greater than 100-200 liters or heavier than 500-1,000 kg)may benefit from keeping the build platform at a fixed height asdescribed in example scenario 700. A similar analysis may be made forother metal powders with different densities.

Furthermore, the thickness of a powder layer may typically be around theorder of 25 microns. Maintaining accuracy and repeatability layer bylayer at this level may be difficult when indexing a powder bed that issupporting a wide-range variable mass.

FIG. 8 illustrates an example scenario 800 of an intermediate point in apowder bed fusion additive manufacturing printing process in accordancewith the present disclosure. Example scenario 800 may be similar toexample scenario 700, showing upward movements of additional componentsin the build chamber while controlling the depth of field with astationary build platform 830. Build platform 830 may have an area of0.5 meter by 1 meter on which powders may be dispensed during a printcycle. In one embodiment, build platform 830 is moved into positionbeneath gantry table 805 and locked into position. Vertical columns803(1)-803(4), each of which at a height of 3 meters, support a gantry807 mounted on the gantry table 805. A powder dispensing unit 810, acompacting functionality 811, and a mirror 817, which may be part ofoptical-mechanical assembly 430, 432, 434 and/or 436 in example scenario400, may be mounted on gantry 807 for translational movements in ahorizontal plane. Gantry table 805 is shown at a position higher abovepowder bed 820 in FIG. 8 to reflect that printing may be in progress.Powder bed 820 contains both powder layers and printed object(s) invarious stages of completion. A new layer of powders 825 is dispensedfrom powder dispensing unit 810 that includes powder spreading andcompacting. Beam 821 incident from print head (not shown) may bereflected off a mirror 817 to become beam 822 impinging upon a location823 in the new layer of powders 825. Printing can occur by melting,sintering, fusing, or otherwise amalgamating of powders at location 823in the new layer of powders 825. The distance between mirror 817 and thelocation 823 in the new layer of powders 825 is the depth of field thatneeds to be tightly controlled to satisfy a resolution requirement. Anarrow 870 indicates an upward movement of gantry table 805, whichsupports gantry 807, powder dispensing unit 810, mirror 817, and incertain embodiments, a surrounding chamber or wall. During this process,the build platform 830 remains locked into place, and the gantry 807(and/or chamber and chamber wall) moves relative the build platform 830.This arrangement is particularly useful for embodiments discussed below,in which the build platform 830 is large, and will need to support alarge amount of heavy material that is not easily moved in a verticaldirection with required precision.

In some embodiments, build platform 830 of example scenario 800 may havean area of more than 0.25 square meters. Alternatively, build platform830 of example scenario 800 may have an area of more than 0.5 squaremeters. Alternatively, build platform 830 of example scenario 800 mayhave an area of more than 1 square meters. Alternatively, build platform830 of example scenario 800 may have an area of more than 5 squaremeters. Alternatively, build platform 830 of example scenario 800 mayhave an area of more than 10 square meters. Alternatively, buildplatform 830 of example scenario 800 may have an area of more than 50square meters.

In some embodiments, powder bed 820 including the printed object ofexample scenario 800 may have a mass of more than 10 kilograms.Alternatively, powder bed 820 including the printed object of examplescenario 800 may have a mass of more than 50 kilograms. Alternatively,powder bed 820 including the printed object of example scenario 800 mayhave a mass of more than 100 kilograms. Alternatively, powder bed 820including the printed object of example scenario 800 may have a mass ofmore than 500 kilograms. Alternatively, powder bed 820 including theprinted object of example scenario 800 may have a mass of more than1,000 kilograms. Alternatively, powder bed 820 including the printedobject of example scenario 800 may have a mass of more than 5,000kilograms. Alternatively, powder bed 820 including the printed object ofexample scenario 800 may have a mass of more than 10,000 kilograms.

In some embodiments, build platform 830 of example scenario 800 may havean area of more than 0.25 square meters and powder bed 820 including theprinted object of example scenario 800 may have a mass of more than 10kilograms.

Powder bed fusion technique process powdered materials to form integralobjects out of metal, ceramic, and plastic powders. Sufficient energiesare needed to bring powders to the respective melting/sintering/alloyingtemperatures, or phase transition temperatures. If a powdered materialstarts out closer to its phase transition temperature, less energy maybe required to complete the phase transition. The powder bed fusionadditive manufacturing may benefit from pre-heating of the powder bed toreduce the amount of energy delivered by the lasers or other energysources. This may allow using a lower intensity laser and less dwelltime to bond a powder, increasing the throughput rate.

Post processing heat treatments may be required for some powderedmaterials such as metals to mitigate stress concentrations and increasemechanical strengths. Post processing heat treatments may include acontrolled-temperature anneal or a fast cooling to improve desiredmechanical or electrical properties. Pre-heating of powders and postprocessing heat treatments may be achieved by embedding heating/coolingelement(s)/temperature sensor(s) inside walls of a build chamber/insidea build platform and controlling the rate of heating/cooling with afeedback algorithm. Heat loss may be reduced by using insulatingmaterials inside walls of a build chamber.

Build chambers 420, 422, 424 and 426 of example scenario 400 may beimplemented as build chambers in scenarios 500, 600, 700 and 800described above and scenario 900 described below, as well as buildchambers 1020(1)-1020(N) of example apparatus described below.Therefore, functions and capabilities of build chambers 420, 422, 424and 426 apply to build chambers in scenarios 500, 600, 700 and 800described above and scenario 900, as well as build chambers1020(1)-1020(N) of example apparatus described below. Accordingly, forthe interest of brevity, functions and capabilities other than for buildchambers 420, 422, 426 and 426 are not provided below to avoidredundancy.

Build platform 530 of example scenario 500 may be implemented as buildplatform 630 of example scenario 600, build platform 730 of examplescenario 700, build platform 830 of example scenario 800, build platform1 of example scenario 900, as well as build platform 1024(1)-1024(N) ofexample apparatus described below. Therefore, functions and capabilitiesof build platform 530 apply to build platform 630 of example scenario600, build platform 730 of example scenario 700, build platform 830 ofexample scenario 800, build platform 1 of example scenario 900, as wellas build platform 1024(1)-1024(N) of example apparatus described below.Accordingly, for the interest of brevity, functions and capabilitiesother than for build platform 530 are not provided below to avoidredundancy.

In some embodiments, each of build chamber 420, 422, 424 and 426 mayinclude resistive heating elements embedded inside in the walls/ceilingsof build chamber 420, 422, 424 and 426.

In some embodiments, each of build chamber 420, 422, 424 and 426 mayinclude active thermal regulation systems such as fluid channelsembedded inside in the walls/ceilings of build chamber 420, 422, 424 and426. The fluid may be heated or cooled outside build chamber 420, 422,424 and 426, and perform heat exchange with the walls/ceilings by movingfluid through the fluid channel. The fluid may include, but not limitedto, an oil, water, steam, air, nitrogen, argon, or a coolant.

In some embodiments, each of build chamber 420, 422, 424 and 426 mayinclude active thermal regulation systems such as thermionic coolingelements embedded inside in the walls/ceilings of build chamber 420,422, 424 and 426.

In some embodiments, each of build chamber 420, 422, 424, and 426 mayinclude thermocouples embedded inside in the walls/ceilings of buildchamber 420, 422, 424 and 426 to monitor temperatures inside buildchambers 420, 422, 424 and 426.

In some embodiments, build platform 530 may include resistive heatingelements embedded inside build platform 530.

In some embodiments, build platform 530 and walls 510, 514, 516 mayinclude active thermal regulation systems such as fluid channelsembedded inside build platform. The fluid may be heated or cooledoutside build platform 530 and walls 510, 514, 516, and perform heatexchange with the walls/ceilings by moving fluid through the fluidchannel. The fluid may include, but not limited to, an oil, water,steam, air, nitrogen, argon, or a coolant.

In some embodiments, build platform 530 and walls 510, 514, 516 mayinclude active thermal regulation systems such as thermionic coolingelements embedded inside build platform 530.

In some embodiments, each of build platform 530 and walls 510, 514, 516may include thermocouples embedded inside build platform 530 to monitortemperatures of powder bed 520.

In some embodiments, each of build chamber 420, 422, 424 and 426 mayinclude an infrared camera looking at a powder bed to monitortemperatures of the powder bed.

In some embodiments, each of build chamber 420, 422, 424 and 426 mayinclude an infrared camera looking at the walls/ceilings of buildchamber 420, 422, 424 and 426 through its own optic system.

In some embodiments, each of build chamber 420, 422, 424 and 426 mayinclude an infrared camera spliced into beam 450 through spectral orpolarization beam combining.

In some embodiments, each of build chamber 420, 422, 424 and 426 mayinclude radiation shields on the walls/ceilings of build chamber 420,422, 424 and 426 to reduce heat loss.

In some embodiments, each of build chamber 420, 422, 424 and 426 mayinclude passive thermal regulation systems such as low thermalconductance materials as part of walls/ceilings of build chamber 420,422, 424 and 426 to reduce heat loss.

In some embodiments, each of build chamber 420, 422, 424 and 426 may becapable of controlling the thermal environment of the powder bed fusionbefore, during, and after a print process using active or passivethermal regulation systems.

FIG. 9 illustrates example scenario 900 of controlling a temperature ofpowder bed 2 using infrared camera 20 and processor 8 during a build. InFIG. 9, build platform 1 may be one square meter in area which supportspowder bed 2. Infrared camera 20 may be mounted on one of the wallsinside a build chamber. Infrared light beam 25, emitted from print area26, may travel back up the print system optics through final lens 24 andmirror 22 into beam 21. Final lens 24 and mirror 22 may be mounted onbuild platform gantry 23. Beam 21 may be split off by hot/cold mirror19, which may transmit 1000 nm light and reflects wavelengths above 1100nm, into beam 27 and beam 29. Infrared camera 20 may read a temperatureof powder bed 2 from beam 29. Processor 8 may receive data via cable 19from infrared camera 20. Processor 8 may further control heating/coolingelement inside build platform 1 to maintain a target temperature ofpowder bed 2.

FIG. 10 illustrates an example apparatus of laser-based powder bedfusion additive manufacturing system 1000 in accordance with anembodiment of the present disclosure. Laser-based powder bed fusionadditive manufacturing system 1000 may perform various functions relatedto techniques, methods and systems described herein, including thosedescribed above with respect to scenario 400, 500, 600, 700, 800 and 900as well as those described below with respect to process 1100.Laser-based powder bed fusion additive manufacturing system 1000 may beimplemented in scenario 400, 500, 600, 700, 800 and 900 to effectvarious embodiments in accordance with the present disclosure.Laser-based powder bed fusion additive manufacturing system 1000 mayinclude at least some of the components illustrated in FIG. 10.

In some embodiments, laser-based powder bed fusion additivemanufacturing system 1000 may include one or more build chambers. Forillustrative purpose and without limitation, one or more build chambersof system 1000 are shown in FIG. 10 as build chambers 1020(1)-1020(N),with N being a positive integer greater than or equal to 1. Buildchambers 1020(1)-1020(N) may include powder dispensing units1022(1)-1022(N) for dispensing powdered materials and build platforms1024(1)-1024(N) to support powder beds formed by powdered materials.Each of build chambers 1020(1)-1020(N) may have a different size and maybe swappable among each other within powder bed fusion additivemanufacturing system 1000. Build chambers 1020(1)-1020(N) may haveremovable doors to facilitate powder removal from a side of buildchambers 1020(1)-1020(N) after a build. Build chambers 1020(1)-1020(N)may be sealed in an atmosphere during powder bed fusion additivemanufacturing. The atmosphere may include, but not limited to, air,nitrogen, argon, or helium.

In some embodiments, walls/ceilings of build chambers 1020(1)-1020(N)may be embedded with heating/cooling elements 1026(1)-1026(N) andtemperature sensors 1028(1)-1028(N) to control the thermal environmentinside build chambers 1020(1)-1020(N).

In some embodiments, heating/cooling elements 1026(1)-1026(N) may befluid channels capable of heat exchange. The fluid may be heated orcooled outside build chambers 1020(1)-1020(N) and perform heat exchangewith the walls/ceilings by moving fluid through the fluid channels. Thefluid may include, but not limited to, an oil, water, steam, air,nitrogen, argon, or a coolant.

In some embodiments, heating/cooling elements 1026(1)-1026(N) may beresistive heating elements and thermionic cooling elements respectively.

In some embodiments, temperature sensors 1028(1)-1028(N) may bethermocouples embedded inside walls/ceilings of inside build chambers1020(1)-1020(N).

In some embodiments, temperature sensors 1028(1)-1028(N) may be infraredcamera(s) mounted on walls/ceilings inside build chambers1020(1)-1020(N).

In some embodiments, each of build chambers 1020(1)-1020(N) may includeradiation shields on walls/ceilings of build chambers 1020(1)-1020(N) toreduce heat loss.

In some embodiments, build chambers 1020(1)-1020(N) may include lowthermal conductance materials as parts of walls/ceilings.

In some embodiments, each of build platforms 1024(1)-1024(N) may becapable of vertical motions or being fixed at a given height duringpowder bed fusion additive manufacturing. Build platforms1024(1)-1024(N) may have different sizes and support variable masses ofpowder beds. Build platforms 1024(1)-1024(N) may be removable from buildchambers 1020(1)-1020(N) on rails, wheels or other means.

In some embodiments, each of build platforms 1024(1)-1024(N) may beembedded with heating/cooling elements 1025(1)-1025(N) and temperaturesensors 1027(1)-1027(N).

In some embodiments, heating/cooling elements 1025(1)-1025(N) may befluid channels capable of heat exchange. The fluid may be heated orcooled outside build chambers 1020(1)-1020(N) and perform heat exchangewith the walls/ceilings by moving fluid through the fluid channels. Thefluid may include, but not limited to, an oil, water, steam, air,nitrogen, argon, or a coolant.

In some embodiments, heating/cooling elements 1025(1)-1025(N) may beresistive heating elements and thermionic cooling elements respectively.

In some embodiments, temperature sensors 1027(1)-1027(N) may bethermocouples embedded inside walls/ceilings of inside build chambers1020(1)-1020(N).

In some embodiments, each of build platforms 1024(1)-1024(N) may have anarea of more than 0.25 square meters. Alternatively, each of buildplatforms 1024(1)-1024(N) may have an area of more than 0.5 squaremeters. Alternatively, each of build platforms 1024(1)-1024(N) may havean area of more than 1 square meters. Alternatively, each of buildplatforms 1024(1)-1024(N) may have an area of more than 5 square meters.Alternatively, each of build platforms 1024(1)-1024(N) may have an areaof more than 10 square meters. Alternatively, each of build platforms1024(1)-1024(N) may have an area of more than 50 square meters. In someembodiments, each of build platforms 1024(1)-1024(N) may support a massof more than 10 kilograms. Alternatively, each of build platforms1024(1)-1024(N) may support a mass of more than 50 kilograms.Alternatively, each of build platforms 1024(1)-1024(N) may support amass of more than 100 kilograms. Alternatively, each of build platforms1024(1)-1024(N) may support a mass of more than 500 kilograms.Alternatively, each of build platforms 1024(1)-1024(N) may support amass of more than 1,000 kilograms. Alternatively, each of buildplatforms 1024(1)-1024(N) may support a mass of more than 5,000kilograms. Alternatively, each of build platforms 1024(1)-1024(N) maysupport a mass of more than 10,000 kilograms.

In some embodiments, each of build platforms 1024(1)-1024(N) may have anarea of more than 0.25 square meters and build platforms 1024(1)-1024(N)may support a mass of more than 10 kilograms.

Powder bed fusion additive manufacturing system 1000 may includeoptical-mechanical assemblies 1030(1)-1030(N) associated with buildchambers 1020(1)-1020(N) respectively for directing incident beams ontorespective build area inside build chambers 1020(1)-1020(N).

Optical-mechanical assemblies 1030(1)-1030(N) may include convex lenses,concave lenses, mirrors, electro-optic components, polarization controlcomponents, and other reflective/refractive components.Optical-mechanical assemblies 1030(1)-1030(N) may further include amechanical structure configured to support and adjust positions orangles of convex lenses, concave lenses, mirrors, and otherreflective/refractive components.

In some embodiments, optical-mechanical assemblies 1030(1)-1030(N) maybe height adjustable in a vertical direction during powder bed fusionadditive manufacturing.

Powder bed fusion additive manufacturing system 1000 may include printhead 1010 capable of providing one or more incident beams to buildchambers 1020(1)-1020(N). Print head 1010 may further include energysource 1050 and beam steering driver(s) 1055. Energy source 1050 may belaser, electron beam, or another suitable source capable of generatingenough beam intensity to melt/sinter/alloying powdered materials. Beamsteering driver(s) may include reflective/refractive optical componentsto split a main beam into multiple incident beams for respective buildchambers 1020(1)-1020(N).

In some embodiments, print head 1010 may be height adjustable in avertical direction together with optical-mechanical assemblies1030(1)-1030(N) during powder bed fusion additive manufacturing.

In some embodiments, powder bed fusion additive manufacturing system1000 may include memory device 1040 configured to store 3D object data1041, programs/instructions for print head control 1042, build platformcontrol 10443, optical-mechanical assembly control 1044, and buildchamber control 1045. 3D object data 1041 may contain geometricalinformation of two dimensional slices of a 3D object. Print head control1042 may contain means for controlling an intensity, a direction, atimed duration of incident beams. Build platform control may containprograms for controlling a temperature and a height of a respectivebuild platform. Optical-mechanical assembly control may contain programsfor controlling a height of a respective optical-mechanical assembly anda location of the incident beam on a powder bed. Build chamber control1045 may contain programs for controlling powder dispensing and atemperature of the powder bed inside a respective build chamber,

In some embodiments, powder bed fusion additive manufacturing system1000 may include a processor 1001. Processor 1001 may be coupled tomemory device 1040 to access data stored therein and to execute anyprograms/instructions stored therein. Processor 1001 may determine howmany 3D objects can be printed concurrently based on total energyrequirement of bonding the powdered materials that form the 3D objects.Processor 1001 may then determine an intensity and a timed duration ofthe respective incident beam for each 3D object. Assignments of buildchambers 1020(1)-1020(N) for the 3D objects to be printed concurrentlymay be based on the size of the 3D object or based on previouslyprocessed powdered materials inside build chambers 1020(1)-1020(N).Processor 1001 may execute print head control 1042 to set an intensityand a timed duration for an incident beam, and beam steering drive(s)1055 may direct each incident beam towards the respective build chamber.Processor 1001 may receive 3D object data from memory 1040 to coordinatemovements of optical-mechanical assemblies 1030(1)-1030(N) according tothe geometrical information of two dimensional slices of the 3D object.Optical-mechanical assembly control 1044 may focus the incident beam onthe top surface of the powder bed and allow the incident beam followingthe geometrical information of two dimensional slices during powder bedfusion additive manufacturing. Processor 1001 may further execute buildchamber control 1045 to control powder dispensing such as layerthickness, rate of dispensing, and compaction. Temperature data fromtemperature sensors 1028(1)-1028(N) may be received by processor 1001and a temperature control algorithm in build chamber control 1045 maydetermine to heat or cool the respective build chamber according toprocessing requirements. During a build, processor 1001 may executebuild platform control 1043 to index build platforms 1024(1)-1024(N)downwards to maintain an essentially constant depth of field as layersof powders are being successively dispensed on to the powder bed.

In some embodiments, build platforms 1024(1)-1024(N) may be locked at afixed height during a build as layers of powders are being successivelydispensed onto the powder bed. Processor 1001 may control print head1010 and optical-mechanical assemblies 1030(1)-1039(N) indexing upwardsto maintain an essentially constant depth of field as opposed todownward movements of build platforms 1024(1)-1024(N).

FIG. 11 illustrates an example process 1100 in accordance with thepresent disclosure. Process 1100 may be utilized to print one or more 3Dobjects concurrently in accordance with the present disclosure. Process1100 may include one or more operations, actions, or functions shown asblocks such as 1110, 1120, 1130, 1140, 1150, and 1160. Althoughillustrated as discrete blocks, various blocks of process 1100 may bedivided into additional blocks, combined into fewer blocks, oreliminated, depending on the desired implementation, and may beperformed or otherwise carried out in an order different from that shownin FIG. 11. Process 1100 may be implemented by powder bed fusionadditive manufacturing system 1000. For illustrative purposes andwithout limiting the scope of process 1100, the following description ofprocess 1100 is provided in the context of scenario 400 as beingimplemented powder bed fusion additive manufacturing system 1000.Process 1100 may begin with block 1110.

At 1110, process 1100 may involve operator(s) of a powder bed fusionadditive manufacturing system 1000 loading one or more build chambers ofbuild chamber 1020(1)-1020(N) with one or more powdered materials toprint one or more 3D objects respectively. The powdered materials mayinclude metal, ceramic, and plastics powders. Assignments of buildchamber 1020(1)-1020(N) for the 3D objects may be based on the size ofthe 3D object. Process 1100 may further involve processor 1001 of powderbed fusion additive manufacturing system 1000 obtaining 3D object data1041 for the one or more 3D objected to be printed. Process 1100 mayproceed from 1110 to 1120.

At 1120, process 1100 may involve processor 1001 bonding the powderedmaterials to form the one or more 3D objects with a correspondingintensity of energy. Different powdered materials may require differentamounts of energy for bonding as melting points or phase transitiontemperatures may be different. Energy source 1050 of powder bed fusionadditive manufacturing system 1000 may have a limit on the outputintensity and may not be exceed during concurrent printing. Process 1100may proceed from 1120 to 1130.

At 1130, process 1100 may involve processor 1001 grouping the one ormore 3D objects into one or more groups. Each group may include a subsetof the one or more 3D objects having a summation of correspondingminimum intensity of energy less than or equal to the maximum outputintensity of energy source 1050. Process 1100 may proceed from 1130 to1140.

At 1140, process 1100 may involve processor 1001 arranging an order ofone or more print jobs of the one or more groups according a result ofgrouping. Process 1100 may proceed from 1140 to 1150.

At 1150, process 1100 may involve powder bed fusion additivemanufacturing system 1000 printing a subset of the one or more 3Dobjects in each group concurrently according to the order of the one ormore print jobs. Process 1100 may further involve processor 1001controlling powder dispensing unit 1022(1)-1022(N), controlling printhead 1010, controlling heights and positions of optical-mechanicalassembly 1030(1)-1030(N), and controlling temperatures of build platform1024(1)-1024(N) as those described in example scenario 400, 550, 600,700, 800, and 900 during the print job. Process 1100 may proceed from1150 to 1160.

At 1160, processor 1100 may involve operator(s) of powder bed fusionadditive manufacturing system 1000 removing printed 3D objects andremaining powders from build chamber 1020(1)-1020(N) upon completion ofa print job to make respective build chambers available. The removal ofprinted 3D objects and remaining powders may be performed as illustratedin example scenario 500 from a side of the respective build chambers bytaking out build platform 530 on rails or wheels.

Many modifications and other embodiments of the invention will come tothe mind of one skilled in the art having the benefit of the teachingspresented in the foregoing descriptions and the associated drawings.Therefore, it is understood that the invention is not to be limited tothe specific embodiments disclosed, and that modifications andembodiments are intended to be included within the scope of the appendedclaims. It is also understood that other embodiments of this inventionmay be practiced in the absence of an element/step not specificallydisclosed herein.

1. An apparatus, comprising: a print head comprising an energy sourcecapable of providing one or more two-dimensional patterned incidentbeams of sufficient energy to process a plurality of powdered materials;a plurality of build chambers, each of the build chambers configured toat least partially surround a plurality of build platforms able to holda powder bed formed by a powdered material; and a plurality ofoptical-mechanical assemblies arranged to receive and direct the one ormore incident beams into the build chambers respectively.
 2. Theapparatus of claim 1, wherein the build platform is height adjustable.3. The apparatus of claim 1, wherein at least one build chamber isconfigured to accommodate side removal of the build platform.
 4. Theapparatus of claim 1, wherein at least one the plurality of buildchambers further comprises a thermal regulation system including atleast one of a plurality of heating sources and a plurality of coolingcomponents embedded in the build platforms and one or more walls formingthe build chambers.
 5. The apparatus of claim 4, wherein the buildchambers further comprise a plurality of temperature sensors embedded inthe build platforms and the one or more walls.
 6. The apparatus of claim4, wherein the build chambers further comprise an insulating or lowthermal-conductivity material built into the one or more walls.
 7. Theapparatus of claim 1, wherein each of the build chambers furthercomprises a dispensing assembly to dispense a layer of the respectivepowdered material on a top surface of the respective powder bed insidethe respective build chamber.
 8. The apparatus of claim 1, wherein atleast one of the build platforms is set at a fixed height, and at leastone of the optical mechanical assemblies are moved in a verticaldirection to focus and direct one of the one or more incident beams ontoa top surface of the respective powder bed inside a respective buildchamber.
 9. The apparatus of claim 1, further comprising: a processorconfigured to control the print head, the optical-mechanical assemblies,and the build chambers to perform additive manufacturing.
 10. Theapparatus of claim 9, wherein, in controlling the print head, theprocessor is configured to control an intensity, a direction, and aduration of the one or more incident beams generated by the energysource during a print process.
 11. The apparatus of claim 9, wherein, incontrolling the optical-mechanical assemblies, the processor isconfigured to control a beam size and a coordinate of at least one ofthe one or more incident beams on a top surface of the respective powderbed inside each of the build chambers during a print process.
 12. Theapparatus of claim 9, wherein, in controlling the build chambers, theprocessor is configured to control a temperature of the respectivepowder bed inside each of the build chambers, and to control a distancefrom a top surface of the respective powdered bed to a corresponding oneof the optical-mechanical assemblies during a print process.
 13. Anapparatus, comprising: a print head comprising an energy source capableof providing one or more two-dimensional patterned incident beams and anoptical-mechanical assembly arranged to receive and direct the one ormore two-dimensional patterned incident beams; a build platform to holda powder bed formed by a powdered material; and an optical-mechanicalassembly movable in a vertical direction to focus and direct one of theone or more two-dimensional patterned incident beams onto a top surfaceof the powder bed inside the build platform.
 14. The apparatus of claim13, wherein the build platform is height adjustable.
 15. The apparatusof claim 13, wherein the build platform is maintained at a fixed height.16. The apparatus of claim 13, further comprising a build chamber to atleast partially surround the build platform.
 17. The apparatus of claim13, wherein the build platform is maintained at a fixed height andfurther comprising a build chamber to at least partially surround thebuild platform, with the build chamber being movable with respect to thebuild platform.
 18. The apparatus of claim 13, further comprising aplurality of build chambers and build platforms.
 19. The apparatus ofclaim 13, wherein the build platform is configured to accommodate a sideremoval of at least one of a printed object formed on the build platformor the build platform.
 20. An apparatus, comprising: a print headcomprising an energy source capable of providing one or moretwo-dimensional patterned incident beams of sufficient energy to processa plurality of powdered materials; a plurality of build chambers, eachof the build chambers configured to at least partially surround a buildplatform able to hold a powder bed formed by a powdered material; aplurality of optical-mechanical assemblies arranged to receive anddirect the one or more two-dimensional patterned incident beams into thebuild chambers respectively; and a thermal regulation system for activeheating or cooling of at least one of the plurality of build chambers.